Semiconductor device and method of forming a 3D interposer system-in-package module

ABSTRACT

A semiconductor device has a first substrate and a second substrate. An opening is formed through the second substrate. A first semiconductor component and second semiconductor component are disposed between the first substrate and second substrate. The second substrate is electrically coupled to the first substrate through the first semiconductor component. A first terminal of the first semiconductor component is electrically coupled to the first substrate. A second terminal of the first semiconductor component is electrically coupled to the second substrate. The second semiconductor component extends into the opening. An encapsulant is deposited over the first substrate and second substrate.

CLAIM OF DOMESTIC PRIORITY

The present application is a continuation of U.S. patent applicationSer. No. 15/976,455, now U.S. Pat. No. 10,797,039, filed May 10, 2018,which is a continuation-in-part of U.S. patent application Ser. No.15/830,644, now U.S. Pat. No. 10,388,637, filed Dec. 4, 2017, whichclaims the benefit of U.S. Provisional Application No. 62/431,219, filedDec. 7, 2016, which applications are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates in general to semiconductor devices and,more particularly, to a semiconductor device and method of forming 3Dinterposer system-in-package (SiP) modules.

BACKGROUND OF THE INVENTION

Semiconductor devices are commonly found in modern electronic products.Semiconductor devices perform a wide range of functions such as signalprocessing, high-speed calculations, transmitting and receivingelectromagnetic signals, controlling electronic devices, photoelectricgeneration, and creating visual images for television displays.Semiconductor devices are found in the fields of communications, powerconversion, networks, computers, entertainment, and consumer products.Semiconductor devices are also found in military applications, aviation,automotive, industrial controllers, and office equipment.

Semiconductor packages may be made with several active semiconductorcomponents, discrete passive components, and integrated passive devices(IPDs) packaged together into a single-package system, sometimes knownas a system-in-package (SiP) module. SiP modules offer higher densityand enhanced electrical functionality relative to traditionalsemiconductor packaging.

The active and passive components of a SiP module are mounted to asubstrate for structural support and electrical interconnect. Thesubstrate and components are encapsulated for environmental protection.The encapsulant at the top surface of the package is generallyplanarized to make a block shaped package. Because the top surface isflat across the devices, the encapsulant surface must be at least ashigh as the tallest component within the SiP module. When tallercomponents are used, more encapsulant is required across the entiredevice, even over shorter components. Encapsulant is wasted over shortercomponents, and semiconductor devices are made physically larger thannecessary. Therefore, a need exists for SiP modules, and methods offorming, taking advantage of unused package space over shortercomponents.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 a-1 c illustrate a semiconductor wafer with a plurality ofsemiconductor die separated by a saw street;

FIGS. 2 a-2 d illustrate a process of forming interposer units for usein system-in-package (SiP) modules;

FIGS. 3 a-3 b illustrate forming a bottom substrate for the SiP modules;

FIGS. 4 a-4 c illustrate forming SiP modules with the interposer unitsover the bottom substrates;

FIG. 5 illustrates a completed SiP module;

FIGS. 6 a-6 b illustrate alternative process options for manufacturingthe SiP modules;

FIG. 7 illustrates a SiP module with conductive pillars as the verticalinterconnect structure between the interposer and bottom substrate;

FIG. 8 illustrates a SiP module with solder balls as the verticalinterconnect structure;

FIGS. 9 a-9 d illustrate forming a SiP module with copper balls as thevertical interconnect structure;

FIG. 10 illustrates a SiP module with an inductor mounted on contactpads embedded in the bottom substrate;

FIGS. 11 a-11 c illustrate forming SiP modules with inductors inopenings of the bottom substrate

FIGS. 12 a-12 c illustrate forming SiP modules without the bottomsubstrate

FIG. 13 illustrates a SiP module with an electromagnetic interference(EMI) shielding layer;

FIG. 14 illustrates a SiP module with an alternate organization ofcomponents;

FIGS. 15 a-15 b illustrate a printed circuit board (PCB) with a SiPmodule mounted to a surface of the PCB;

FIGS. 16 a-16 e illustrate forming a SiP module with vertically orienteddiscrete devices;

FIGS. 17 a and 17 b illustrate a SiP module with horizontally orienteddiscrete devices that are coupled vertically;

FIG. 18 illustrates a SiP module with discrete devices supporting aninterposer substrate;

FIG. 19 illustrates another embodiment with discrete devices supportingan interposer substrate;

FIG. 20 illustrates a SiP module with an embedded inductor and verticaldiscrete devices;

FIG. 21 illustrates a SiP module with an embedded inductor and aninterposer substrate overlying the inductor; and

FIG. 22 illustrates an embodiment with a shielding layer.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention is described in one or more embodiments in thefollowing description with reference to the figures, in which likenumerals represent the same or similar elements. While the invention isdescribed in terms of the best mode for achieving the invention'sobjectives, it will be appreciated by those skilled in the art that itis intended to cover alternatives, modifications, and equivalents as maybe included within the spirit and scope of the invention as defined bythe appended claims and their equivalents as supported by the followingdisclosure and drawings.

The term “semiconductor die” as used herein refers to both the singularand plural form of the words, and accordingly, can refer to both asingle semiconductor device and multiple semiconductor devices. The term“semiconductor component,” or simply “component,” as used herein refersto active devices formed in semiconductor die, packages formed usingsemiconductor die, discrete active or passive devices, integrated activeor passive circuits, or any other active or passive electrical part.

Semiconductor devices are generally manufactured using two complexmanufacturing processes: front-end manufacturing and back-endmanufacturing. Front-end manufacturing involves the formation of aplurality of die on the surface of a semiconductor wafer. Each die onthe wafer contains active and passive electrical components, which areelectrically connected to form functional electrical circuits. Activeelectrical components, such as transistors and diodes, have the abilityto control the flow of electrical current. Passive electricalcomponents, such as capacitors, inductors, and resistors, create arelationship between voltage and current necessary to perform electricalcircuit functions.

Back-end manufacturing refers to cutting or singulating the finishedwafer into the individual semiconductor die and packaging thesemiconductor die for structural support, electrical interconnect, andenvironmental isolation. To singulate the semiconductor die, the waferis scored and broken along non-functional regions of the wafer calledsaw streets or scribes. The wafer is singulated using a laser cuttingtool or saw blade. After singulation, the individual semiconductor dieare mounted to a package substrate that includes pins or contact padsfor interconnection with other system components. Contact pads formedover the semiconductor die are then connected to contact pads within thepackage. The electrical connections can be made with conductive layers,bumps, stud bumps, conductive paste, or wirebonds. An encapsulant orother molding material is deposited over the package to provide physicalsupport and electrical isolation. The finished package is then insertedinto an electrical system and the functionality of the semiconductordevice is made available to the other system components.

FIG. 1 a shows a semiconductor wafer 100 with a base substrate material102, such as silicon, germanium, aluminum phosphide, aluminum arsenide,gallium arsenide, gallium nitride, indium phosphide, silicon carbide, orother bulk material for structural support. A plurality of semiconductordie or components 104 is formed on wafer 100 separated by a non-active,inter-die wafer area or saw street 106. Saw street 106 provides cuttingareas to singulate semiconductor wafer 100 into individual semiconductordie 104. In one embodiment, semiconductor wafer 100 has a width ordiameter of 100-450 millimeters (mm).

FIG. 1 b shows a cross-sectional view of a portion of semiconductorwafer 100. Each semiconductor die 104 has a back or non-active surface108 and an active surface 110 containing analog or digital circuitsimplemented as active devices, passive devices, conductive layers, anddielectric layers formed within or over the die and electricallyinterconnected according to the electrical design and function of thedie. The circuits may include one or more transistors, diodes, and othercircuit elements formed within active surface 110 to implement analogcircuits or digital circuits, such as a digital signal processor (DSP),application specific integrated circuit (ASIC), memory, or other signalprocessing circuit. Semiconductor die 104 may also contain IPDs, such asinductors, capacitors, and resistors formed in or on interconnect layersover surfaces of the semiconductor die for RF signal processing or otherpurposes. In some embodiments, semiconductor die 104 include multipleactive surfaces with circuits formed in or on each active surface.

An electrically conductive layer 112 is formed over active surface 110using PVD, CVD, electrolytic plating, electroless plating, or othersuitable metal deposition process. Conductive layer 112 can be one ormore layers of aluminum (Al), copper (Cu), tin (Sn), nickel (Ni), gold(Au), silver (Ag), or other suitable electrically conductive material.Conductive layer 112 operates as contact pads electrically connected tothe circuits of active surface 110.

An electrically conductive bump material is deposited over conductivelayer 112 using an evaporation, electrolytic plating, electrolessplating, ball drop, or screen printing process. The bump material can beAl, Sn, Ni, Au, Ag, lead (Pb), bismuth (Bi), Cu, solder, or acombination thereof, with an optional flux solution. For example, thebump material can be eutectic Sn/Pb, high-lead solder, or lead-freesolder. The bump material is bonded to conductive layer 112 using asuitable attachment or bonding process. In some embodiments, the bumpmaterial is reflowed by heating the material above its melting point toform balls or bumps 114. In one embodiment, bumps 114 are formed over anunder bump metallization (UBM) having a wetting layer, a barrier layer,and an adhesion layer. Bumps 114 can also be compression bonded orthermocompression bonded to conductive layer 112. Bumps 114 representone type of interconnect structure that can be formed over conductivelayer 112. The interconnect structures can also include bond wires,conductive paste, stud bumps, micro bumps, conductive pillars, or otherelectrical interconnects.

In FIG. 1 c , semiconductor wafer 100 is singulated through saw street106 using a saw blade or laser cutting tool 118 into individualsemiconductor die 104. The individual semiconductor die 104 can beinspected and electrically tested for identification of known good die(KGD) before or after singulation.

FIGS. 2 a-2 d illustrate a process of forming interposer units includingsemiconductor die 104 and other components mounted on the interposerunits for integration in a SiP module. FIG. 2 a shows a cross-sectionalview of substrate 150 including a plurality of regions for formation ofinterposer units separated by saw streets 152. While only two regionsfor forming interposer units are shown, substrate 150 is much larger inother embodiments, with room to form hundreds or thousands of units inparallel. Substrate 150 is formed from a base insulating material 153with conductive layers 154 and 156 formed on the two major surfaces ofthe insulating layer. In one embodiment, insulating material 153 is amolded substrate. In some embodiments, substrate 150 is formed using aplurality of insulating layers 153 interleaved with a plurality ofconductive layers, which allows for more complicated signal routing.Portions of conductive layers 154 and 156 are electrically common orelectrically isolated depending on the design and function of the SiPmodule being formed.

Conductive layers 154 and 156 can be one or more layers of Al, Cu, Sn,Ni, Au, Ag, or other suitable electrically conductive material.Conductive layers 154 and 156 include a plurality of contact pads, e.g.,contact pads 154 a, which can be coupled together by conductive tracesformed as part of the conductive layer, e.g., conductive traces 154 b.Conductive vias 158 extend through insulating layer 153 to electricallyconnect portions of conductive layer 154 to portions of conductive layer156. Conductive layers 154 and 156 provide horizontal electricalinterconnect across substrate 150, while conductive vias 158 providevertical electrical interconnect through substrate 150. In oneembodiment, conductive vias 158 are formed by providing an openingthrough insulating layer 153 by etching, drilling, laser ablation, oranother suitable process, and then depositing or plating conductivematerial into the opening. In some embodiments, conductive material forconductive vias 158 is deposited into openings of insulating layer 153as part of forming conductive layers 154 or 156.

Substrate 150 can also be any suitable laminate interposer, laminatesubstrate, PCB, wafer-form, strip interposer, leadframe, embedded tracesubstrate (ETS), or other type of substrate. Substrate 150 may includeone or more laminated layers of polytetrafluoroethylene (PTFE)pre-impregnated (prepreg), FR-4, FR-1, CEM-1, or CEM-3 with acombination of phenolic cotton paper, epoxy, resin, woven glass, matteglass, polyester, and other reinforcement fibers or fabrics. Insulatinglayer 153 contains one or more layers of silicon dioxide (SiO₂), siliconnitride (Si₃N₄), silicon oxynitride (SiON), tantalum pentoxide (Ta₂O₅),aluminum oxide (Al₂O₃), solder resist, polyimide, benzocyclobutene(BCB), polybenzoxazole (PBO), or other material having similarinsulating and structural properties. Substrate 150 can also be amulti-layer flexible laminate, ceramic, copper clad laminate, glass, ora semiconductor wafer including an active surface containing one or moretransistors, diodes, and other circuit elements to implement analog ordigital circuits.

Substrate 150 includes holes or openings 160 at locations whereinductors, or other taller components, are to be disposed on anunderlying substrate within the SiP module footprint. Openings 160 areformed through substrate 150 using a saw blade, laser cutting tool,water cutting tool, an etching process, or another suitable mechanismfor forming an opening through a substrate. In other embodiments,substrate 150 is formed in a manner that leaves openings 160 through thesubstrate without having to separately form an opening after thesubstrate is manufactured, e.g., molding insulating material 153 toinclude opening 160.

FIG. 2 b illustrates a plan view of substrate 150 from the top of FIG. 2a . Conductive layer 154 includes a plurality of contact pads 154 a forsurface mounting semiconductor die and discrete devices as desired toimplement a given electrical function, and a plurality of conductivetraces 154 b for interconnecting the contact pads per the design andfunction of the SiP module. Conductive layer 154 can include any desirednumber, shape, and layout of contact pads interconnected by conductivetraces in any appropriate manner. In some embodiments, conductive layer156 also includes conductive traces to electrically connect a pluralityof contact pads to each other. Substrate 150 can be tested at thecurrent stage seen in FIGS. 2 a and 2 b , prior to mountingsemiconductor die and other components on the substrate.

In FIG. 2 c , semiconductor die 104 and discrete devices 162 are surfacemounted onto conductive layer 154. In some embodiments, substrate 150 isdisposed on a carrier for installation of semiconductor die 104 anddiscrete devices 162. In other embodiments, substrate 150 is disposed ina jig. Semiconductor die 104 can be tested for KGD prior to mountingonto substrate 150 to avoid using bad die on good substrate deviceregions. In addition, the regions of substrate 150 can be tested priorto mounting components, and regions of the substrate with manufacturingdefects can be discarded without wasting KGD on a bad substrate. In someembodiments, bad or blank semiconductor die 104 are disposed on badregions of substrate 150 to keep weight distribution even across thesubstrate and help control warpage.

FIG. 2 c shows each device region of substrate 150 having two discretedevices 162, which can be inductors, capacitors, resistors, or otherpassive circuit components. Discrete devices 162 can also be deviceswith active functionality, e.g., power transistors, transient voltagesuppression diodes, etc. In other embodiments, any combination of activeand passive devices can be provided on substrate 150 as desired toimplement the intended functionality of a final SiP module. In oneembodiment, discrete devices 162 implement a band-pass filter or anotherradio frequency (RF) signal processing network. In another embodiment,discrete devices 162 filter a power signal to semiconductor die 104.Discrete devices 162 can implement any desired electrical function.Discrete devices 162 operate in conjunction with other components of afinal SiP module in some embodiments.

Discrete devices 162 are mechanically bonded and electrically connectedto contact pads 154 a through solder or solder paste 166. In oneembodiment, solder paste 166 is printed onto substrate 150, opticallyinspected, reflowed with discrete devices 162 in physical contact, andthen defluxed. Discrete devices 162 are dispensed from a tape and reelusing a chip capacitor mounter (CCM) in some embodiments. Theconnections of discrete devices 162 to substrate 150 can be opticallyinspected again after reflow. Semiconductor die 104 are mechanicallybonded and electrically connected to conductive layer 154 throughconductive bumps 114. In some embodiments, bumps 114 and solder paste166 are reflowed at the same time to surface mount all components in asingle step.

In FIG. 2 d , substrate 150 is singulated through saw streets 152 usingsaw blade, laser cutting tool, or water cutting tool 192, into aplurality of interposer units 196. In some embodiments, the singulatedinterposer units 196 are visually inspected and can be packaged into atape and reel for storage and processing in later manufacturing steps.

FIGS. 3 a-3 b illustrate forming a bottom substrate for SiP modules. Theprocess begins in FIG. 3 a with a substrate 200 having locations to forma plurality of bottom substrate submodules separated by saw streets 202.Substrate 200 is similar to substrate 150, and can be any of the varietyof substrate types discussed above. As illustrated, substrate 200includes one or more insulating layers 203 with conductive layers 204and 206 on opposite sides of the substrate. Portions of conductivelayers 204 and 206 are electrically connected to each other byconductive traces within the conductive layers and conductive vias 208through substrate 200. Like substrate 150, bottom substrate 200 can betested prior to mounting components, and the components can be tested inadvance of mounting as well, to reduce waste. Substrate 200 can bedisposed on a carrier or in a jig for subsequent processing.

In FIG. 3 b , discrete devices 162 and 210 are surface mounted ontosubstrate 200 and electrically connected to conductive layer 204 bysolder paste 166 and interconnect structures 212, respectively. Solderpaste 166 is printed onto contact pads of conductive layer 204 and theninspected prior to mounting of discrete devices 162, similar to abovefor substrate 150. Solder paste 166 can be used for discrete device 210in embodiments where interconnect structures 212 are contact pads oranother electrical terminal with a higher reflow temperature than thesolder paste. Interconnect structures 212 are solder bumps reflowedbetween contact pads of discrete devices 210 and conductive layer 204 inanother embodiment. Discrete devices 162 on bottom substrate 200 can beidentical to or different from the discrete devices on interposer units196, and can include any appropriate active or passive component.Discrete devices 210 are components with greater heights than discretedevices 162. Discrete devices 210 are illustrated as inductors, asinductors are commonly the tallest components in many SiP modules.However, discrete devices 210 can be any component that is tall relativeto other components on substrate 200.

Copper core solder balls (CCSB) 214 are disposed on conductive layer 204of substrate 200 as vertical interconnect structures. CCSB 214 include anon-fusible core 214 a formed from Cu or another material that canremain solid when subject to the heat applied to reflow the fusibleshell 214 b. Fusible shell 214 b is a solder material similar to bumps114 in one embodiment, and can be plated or otherwise coated ontonon-fusible cores 214 a. Fusible shell 214 b can be reflowed at the sametime as solder paste 166 and interconnect structures 212 to physicallyand electrically couple CCSB 214, discrete devices 162, and discretedevices 210 to substrate 200 in a common reflow step. In someembodiments, CCSB 214, discrete devices 162, and discrete devices 210are optically inspected on substrate 200 prior to reflow. After reflow,CCSB 214, discrete devices 162, and discrete devices 210 can be defluxedand optically inspected again. In another embodiment, CCSB 214 arecompression bonded to conductive layer 204.

Conductive bumps 220 are formed over substrate 200 opposite discretedevices 162, discrete devices 210, and CCSB 214 on contact pads ofconductive layer 206. Bumps 220 are similar to bumps 114 onsemiconductor die 104, and can be solder bumps, stud bumps, conductivepillars, or another suitable interconnect structure. Conductive bumps220 can be formed prior to or after disposing components on conductivelayer 204. In some embodiments, forming conductive bumps 220 isperformed at a later manufacturing step. Conductive bumps 220 areaffixed to conductive layer 206 by reflowing, compression bonding, oranother suitable means. X-ray inspection can be used to confirm properelectrical connection for all components on substrate 200.

FIGS. 4 a-4 c illustrate a process of combining substrate 200 andinterposer units 196 into SiP modules. In FIG. 4 a , interposer units196 are disposed over the top surface of substrate 200, i.e., thesurface of substrate 200 that discrete devices 162 and 210 are mountedonto. If interposer units 196 were previously stored in a tape and reel,the interposer units can be disposed over substrate 200 using a CCM. Inother embodiments, interposer units 196 are picked and placed from acarrier after singulation in FIG. 2 d . In another embodiment, substrate150 is disposed over substrate 200 without substrate 150 first beingsingulated into individual interposer units 196.

Opening 160 is aligned with the taller discrete devices 210. Opening 160allows interposer units 196 to lie directly on CCSB 214 even though thespace between the interposer units and substrate 200 is insufficient toaccommodate the full height of discrete devices 210. Discrete devices210 extend into openings 160 within the height of interposer units 196.In some embodiments, discrete devices 210 extend to over the top surfaceof interposer units 196.

Fusible shells 214 b of CCSB 214 are reflowed to mechanically andelectrically couple interposer units 196 to substrate 200 through theCCSB. Non-fusible core 214 a remains solid during reflow of fusibleshell 214 b to maintain an offset between substrate 200 and interposerunits 196. In some embodiments, contact pads of conductive layer 156include solder paste printed thereon to improve connection to CCSB 214.

In FIG. 4 b , an encapsulant or molding compound 256 is deposited oversubstrate 200, interposer units 196, semiconductor die 104, discretedevices 162, and discrete devices 210 using a paste printing,compressive molding, transfer molding, liquid encapsulant molding,vacuum lamination, spin coating, or other suitable applicator.Encapsulant 256 can be polymer composite material, such as epoxy resin,epoxy acrylate, or polymer with or without filler. Encapsulant 256 isnon-conductive, provides structural support, and environmentallyprotects the semiconductor device from external elements andcontaminants. Encapsulant 256 flows below semiconductor die 104 betweenconductive bumps 114, below discrete devices 162 between solder paste166, and below discrete devices 210 between interconnect structures 212to completely fill the space between substrate 200 or interposer units196 and the semiconductor die and discrete devices. In otherembodiments, a separate underfill is used for some or all components.

Encapsulant 256 undergoes a post-mold cure in some embodiments, followedby an optional laser marking. The combination of substrate 200 andinterposer units 196 covered with encapsulant 256 forms a panel of SiPmodules. In some embodiments, encapsulant 256 is deposited thicker thannecessary and backgrinded to reduce a thickness of the encapsulant.Backgrinding is performed using chemical mechanical planarization (CMP),an etching process, laser direct ablation (LDA), or another suitablethinning procedure.

In FIG. 4 c , the panel is singulated through substrate 200 andencapsulant 256 at saw streets 252 using saw blade, laser cutting tool,or water cutting tool 258, into a plurality of SiP modules 260. In someembodiments, the panel is cut through a portion of interposer units 196.In other embodiments, the panel is singulated such that a portion ofencapsulant 256 remains between side surfaces of interposer units 196and side surfaces of SiP modules 260.

In one embodiment, bumps 220 are not formed prior to depositingencapsulant 256. The encapsulated panel can be flipped and disposed on acarrier with substrate 200 oriented away from the carrier for bumpingafter encapsulation and before singulation.

FIG. 5 illustrates a singulated SiP module 260. SiP module 260 can belead inspected, and undergo other external visual inspection and testingbefore baking and shipping. Conductive bumps 220 are configured to allowSiP module 260 to be mounted onto a PCB or other substrate of a largerelectronic device for system integration. Discrete devices 162 and 210on substrate 200 are electrically coupled to conductive bumps 220through conductive layer 204, conductive vias 208, and conductive layer206. Discrete devices 162 and semiconductor die 104 of interposer unit196 are coupled to conductive bumps 220 by conductive layer 154,conductive vias 158, conductive layer 156, CCSB 214, conductive layer204, conductive vias 208, and conductive layer 206. In some embodiments,conductive traces of conductive layers 154, 156, 204, or 206electrically couple discrete devices 162, discrete devices 210, andsemiconductor die 104 to each other internal to SiP module 260 in anydesired configuration. In one embodiment, one or more terminals of thediscrete devices 162 on substrate 200 can be directly coupled tointerposer unit 196 by solder paste printed on conductive layer 156, oranother interconnect structure, as illustrated below in FIGS. 16 a-16 e,17 a, 17 b , and 18-22.

SiP module 260 provides a plurality of components, each usable by thelarger electronic device, in a single easy to integrate package.Discrete device 210 is a relatively tall component. Discrete device 210is disposed within a footprint of opening 160, which allows discretedevice 210 and interposer unit 196 to occupy the same vertical dimensionwithout interfering with each other. The height of discrete devices 210extends to within a height of interposer unit 196. In some embodiments,discrete device 210 extends completely over the height of interposerunit 196, and may extend to a height above the tops of discrete devices162 or semiconductor die 104 on interposer unit 196. Opening 160 allowsan interposer to be used over shorter discrete devices 162 withoutinterfering with the taller height of discrete device 210.

The use of interposer units 196 allows additional components within SiPmodule 260 without having to increase the footprint of substrate 200. Insome embodiments, discrete device 210 is so tall that interposer units196 can be added over the shorter discrete devices 162 without adding tothe thickness of SiP module 260. Electrical performance is improved byreducing signal paths relative to having each component spread out on asingle substrate.

FIGS. 6 a and 6 b illustrate two manufacturing variations. In FIG. 6 a ,CCSB 214 are initially disposed or formed on conductive layer 156 ofsubstrate 150 during the manufacturing process of interposer units 196.Interposer units 196 with CCSB 214 are disposed over substrate 200, andthen fusible shell 214 b is bonded to conductive layer 204 throughreflow, compression bonding, or another suitable means. In someembodiments, solder paste is printed onto conductive layer 204 underCCSB 214 to improve the connection. Solder paste for CCSB 214 can beprinted during the same printing process as solder paste 166 fordiscrete devices 162. The structure is encapsulated and singulated asillustrated in FIGS. 4 b-4 c to form a SiP module substantially the sameas in FIG. 5 , but formed with CCSB initially on interposer units 196instead of substrate 200.

FIG. 6 b illustrates forming SiP modules with interposer units 266replacing interposer units 196. Interposer units 266 are formed in asimilar manner to interposer units 196. However, rather than includingopenings 160 formed through the interposer unit, interposer units 266are made with a smaller footprint compared to the size of a unit ofsubstrate 200. The smaller footprint of interposer unit 266 allows roomfor the taller discrete devices 210 to be disposed on substrate 200outside a footprint of the interposer unit. Again, the structure withinterposer units 266 is encapsulated and singulated as illustrated inFIGS. 4 b-4 c to form a SiP module similar to SiP module 260 in FIG. 5 ,but with discrete device 210 adjacent to or completely outside afootprint of the interposer unit rather than in an opening of theinterposer unit.

FIG. 7 illustrates a SiP module 270 with conductive pillars 272 used asthe vertical interconnect structure instead of CCSB 214. Conductivepillars 272 are formed from Cu, Al, Au, Ag, another suitable conductivematerial, or combinations thereof. Conductive pillars 272 are platedonto conductive layer 204 into a mask opening in one embodiment. Soldercaps 274 can be formed by depositing solder or another fusible materialinto the same mask opening used to form conductive pillars 272. Soldercap 274 is bonded to conductive layer 156 by reflow, compressionbonding, or another suitable means. In another embodiment, conductivepillars 272 are plated onto conductive layer 156 and then bonded toconductive layer 204 with solder cap 274.

FIG. 8 illustrates a SiP module 276 that is manufactured using solderballs 275 instead of CCSB 214. Solder balls 275 are a uniform body ofsolder, e.g., Sn—Pb, Sn—Ag, Sn—Ag—Cu, or other suitable soldercompositions. Solder balls 275 reflow completely when attachinginterposer units 196 to substrate 200, unlike CCSB 214 where only theouter shell 214 b reflows. Solder balls 275 do not provide the samedegree of standoff capability as CCSB 214, which have a non-fusiblecore, but are satisfactory for many embodiments.

FIGS. 9 a-9 d illustrate forming a SiP module with copper balls 214 a asthe vertical interconnect, without the solder coating 214 b. In FIG. 9 a, solder or solder paste 166 is printed or otherwise disposed on contactpads of conductive layer 204. Solder paste 166 is provided at locationsfor discrete devices 162 as above, but is also provided at locationswhere vertical interconnect to interposer units 196 is desired. In someembodiments, solder paste 166 is also printed at locations wherediscrete device 210 is to be connected to substrate 200.

In FIG. 9 b , discrete devices 162 and 210 are disposed on substrate 200as in FIG. 3 b . In addition, copper balls 214 a are disposed on contactpads of conductive layer 204 over solder paste 166. As above, copperballs 214 a can be formed from copper or another suitable metal thatdoes not reflow with solder paste 166. Solder paste 166 is reflowed tomechanically bond copper balls 214 a to substrate 200.

In FIG. 9 c , interposer units 196 are disposed over substrate 200 andcopper balls 214 a. Solder paste 166 has previously been disposed onconductive layer 156 at locations to be aligned with copper balls 214 a.Solder paste 166 is reflowed to bond copper balls 214 a to interposerunits 196. The SiP modules are encapsulated and singulated as above,resulting in the SiP module 278 in FIG. 9 d . Copper balls 214 a areused in a similar manner as in SiP module 260, i.e., to provide physicalstandoff as well as electrical interconnection, but are connected with aseparate solder paste 166 rather than a solder coating 214 b.

FIG. 10 illustrates a SiP module 280 with discrete device 210 disposedin a recess 282 of substrate 200 on an intermediate conductive layer284. Substrate 200 in FIG. 10 includes at least one intermediateconductive layer 284 between layers of insulating material 203, andbetween conductive layers 204 and 206 on the top and bottom surfaces ofthe substrate. Intermediate conductive layer 284 can be used tolaterally route electrical signals between conductive layers 204 and 206by including conductive traces as part of conductive layer 284. Portionsof conductive layer 284 are located or extend outside a footprint ofrecess 282 in some embodiments. SiP module 280 is formed insubstantially the same manner as SiP module 260 above, but with discretedevice 210 disposed on conductive layer 284 in recess 282 rather than onconductive layer 204.

In some embodiments, recess 282 is formed by etching away upperinsulating layers 203 to expose the intermediate conductive layer 284.In other embodiments, recess 282 extends completely through insulatingmaterial 203 to expose conductive layer 206, and discrete device 210 isdisposed on conductive layer 206 directly opposite conductive bumps 220.Placing discrete device 210 in a recess lowers the height of discretedevice 210, allowing taller discrete devices 210 without significantlyincreasing the size of the SiP module.

FIGS. 11 a-11 c illustrate forming a SiP module with discrete device 210formed in an opening completely through the bottom substrate. FIG. 11 aillustrates a bottom substrate 290 with opening 292 formed through thesubstrate at locations for the taller discrete devices 210. Substrate290 is substantially the same as substrates 150 and 200 above, andopening 292 is formed through the substrate similarly to opening 160.Substrate 290 is disposed on a carrier 294 with optional thermal releaselayer, double-sided tape, or other interface layer 296. Interface layer296 can include an adhesive property to help keep substrate 290 anddiscrete devices 210 in place during processing. In some embodiments, atape is laminated onto the bottom of substrate 290 to hold components inopening 292 while substrate 290 is disposed in a jig.

Discrete devices 210 are disposed in openings 292 with interconnectstructures 212 in contact with interface layer 296. When carrier 294 andinterface layer 296 are subsequently removed, interconnect structures212 are exposed, along with the contact pads of conductive layer 206,for electrical interconnect. Interconnect structures 212 are contactpads similar to those of conductive layer 206 in one embodiment. Inanother embodiment, interconnect structures 212 are solder bumps similarto bumps 114 or solder paste similar to solder paste 166. Discretedevices 162 and CCSB 214 are mounted on substrate 290, as with substrate200 above, either before or after disposal on carrier 294.

Also as above, interposer units 196 are disposed over each of the unitsof substrate 290 and encapsulated in FIG. 11 b . Carrier 294 andinterface layer 296 are removed by mechanical peeling, thermal release,UV release, or another appropriate mechanism to expose conductive layer206 and interconnect structures 212. Conductive bumps 220 are applied asabove. In embodiments where interconnect structures 212 include solderbumps, interconnect structures 212 can be reflowed together withcorresponding bumps 220 to form a single continuous body of solder.

The panel is singulated through encapsulant 256 and substrate 290 toform individual SiP modules 298 in FIG. 11 c . Opening 292 throughsubstrate 290 allows the use of a discrete device 210 that is nearly thesame height as the entire thickness of SiP module 298 withoutinterference with substrate 290 or interposer unit 196. At the sametime, other shorter components are stacked above each other onto twoseparate substrates, i.e., substrate 290 and interposer unit 196, toincrease component density.

FIGS. 12 a-12 c illustrate forming SiP modules without a bottomsubstrate. In FIG. 12 a , CCSB 214, discrete devices 162, and discretedevices 210 are all disposed directly on carrier 294 and interface layer296. An adhesive property of interface layer 296 is used to hold thecomponents in place in one embodiment. Interposer units 196 are disposedon CCSB 214 as above. The structure is encapsulated to form a panel. Thepanel is optionally flipped onto another carrier for application ofbumps 220, and then singulated in FIG. 12 b.

FIG. 12 c illustrates SiP module 299 singulated from the panel in FIG.12 b . SiP module 299 is similar to the above embodiments, but without abottom substrate. Conductive bumps 220 are disposed directly on CCSB214, interconnect structures 212, and solder paste 166. In someembodiments, solder paste 166 is absent; discrete devices 162 aredisposed directly on interface layer 296 without solder paste 166, andbumps 220 are disposed directly on terminals of discrete devices 162after removal of carrier 294. Conductive bumps 220 are reflowed togetherwith fusible shell 214 b to form a uniform body of solder around core214 a in some embodiments.

FIG. 13 illustrates SiP module 300 with shielding layer 302 formed overthe package. SiP module 300 is similar to SiP module 260, but formedwith a process that allows shielding layer 302 to be plated over thepackages. In one embodiment, shielding layer 302 is sputtered over theSiP modules after singulation in FIG. 4 c , but prior to removing theSiP modules from a carrier for packaging in a tape and reel. Shieldinglayer 302 is optionally electrically coupled to a ground node of anunderlying substrate through a conductive trace 154 b of conductivelayer 154 that is routed to the edge of substrate 150 to contact theshielding layer or a portion 206 a of conductive layer 206. Shieldinglayer 302 may also be coupled to a ground node through conductive layer204 or 156. Shielding layer 302 helps protect components within SiPmodule 300 from interference caused by external sources ofelectromagnetic radiation. Shielding layer 302 may also be used toreduce interference by radiation from SiP module 300 on nearby devicesexternal to the SiP module. Shielding layer 302 is compatible with anyof the above or below described SiP modules.

The actual layout of discrete devices 162, semiconductor die 104, anddiscrete devices 210 is not limited to the disclosed embodiments. Anycombination of active and passive components can be placed on either oneof interposer unit 196 or substrate 200. FIG. 14 illustrates a SiPmodule 310 with semiconductor die 104 disposed on bottom substrate 200rather than interposer unit 196 as above. In other embodiments, onlypassive devices are used. The taller discrete devices 210 can also be inany location within the footprint of a SiP module, and openings 160 areformed through interposer units 196 in corresponding locations.

FIGS. 15 a-15 b illustrate incorporating the above described SiP modulesinto an electronic device. FIG. 15 a illustrates a partial cross-sectionof SiP module 260 from FIG. 5 mounted onto a PCB or other substrate 402as part of an electronic device. Bumps 220 are reflowed onto conductivelayer 504 to physically attach and electrically connect SiP module 260to PCB 402. Any of the above described SiP modules can similarly bemounted onto PCB 402. In other embodiments, thermocompression or othersuitable attachment and connection methods are used. In someembodiments, an adhesive or underfill layer is used between SiP module260 and PCB 402.

Semiconductor die 104 is electrically coupled to conductive layer 404through bumps 114, substrate 150, CCSB 214, substrate 200, and bumps220. Discrete devices 162 and 210 are coupled to conductive layer 404through solder paste 166, interconnect structures 212, substrate 150,CCSB 214, substrate 200, and bumps 220. In some embodiments, substrates150 and 200 couple semiconductor die 104 and discrete devices 162 toeach other. In other embodiments, conductive layer 404 couplessemiconductor die 104, discrete devices 162, and discrete devices 210 toeach other.

FIG. 15 b illustrates electronic device 405 including PCB 402 with aplurality of semiconductor packages mounted on a surface of the PCB,including SiP module 260. Electronic device 405 can have one type ofsemiconductor package, or multiple types of semiconductor packages,depending on the application.

Electronic device 405 can be a stand-alone system that uses thesemiconductor packages to perform one or more electrical functions.Alternatively, electronic device 405 can be a subcomponent of a largersystem. For example, electronic device 405 can be part of a tabletcomputer, cellular phone, digital camera, communication system, or otherelectronic device. Electronic device 405 can also be a graphics card,network interface card, or other signal processing card that is insertedinto a computer. The semiconductor packages can include microprocessors,memories, ASICs, logic circuits, analog circuits, RF circuits, discreteactive or passive devices, or other semiconductor die or electricalcomponents.

In FIG. 15 b , PCB 402 provides a general substrate for structuralsupport and electrical interconnection of the semiconductor packagesmounted on the PCB. Conductive signal traces 404 are formed over asurface or within layers of PCB 402 using evaporation, electrolyticplating, electroless plating, screen printing, or other suitable metaldeposition process. Signal traces 404 provide for electricalcommunication between each of the semiconductor packages, mountedcomponents, and other external systems or components. Traces 404 alsoprovide power and ground connections to each of the semiconductorpackages as needed.

In some embodiments, a semiconductor device has two packaging levels.First level packaging is a technique for mechanically and electricallyattaching the semiconductor die to an intermediate substrate. Secondlevel packaging involves mechanically and electrically attaching theintermediate substrate to PCB 402. In other embodiments, a semiconductordevice may only have the first level packaging where the die ismechanically and electrically mounted directly to PCB 402.

For the purpose of illustration, several types of first level packaging,including bond wire package 406 and flipchip 408, are shown on PCB 402.Additionally, several types of second level packaging, including ballgrid array (BGA) 410, bump chip carrier (BCC) 412, land grid array (LGA)416, multi-chip module (MCM) 418, quad flat non-leaded package (QFN)420, embedded wafer level ball grid array (eWLB) 424, and wafer levelchip scale package (WLCSP) 426 are shown mounted on PCB 402 along withSiP module 260. In one embodiment, eWLB 424 is a fan-out wafer levelpackage (Fo-WLP) and WLCSP 426 is a fan-in wafer level package (Fi-WLP).Conductive traces 404 electrically couple the various packages disposedon substrate 402 to SiP module 260 for access to the components withinthe SiP module.

Depending upon the system requirements, any combination of semiconductorpackages, configured with any combination of first and second levelpackaging styles, as well as other electronic components, can beconnected to PCB 402. In some embodiments, electronic device 405includes a single attached semiconductor package, while otherembodiments call for multiple interconnected packages. By combining oneor more semiconductor packages over a single substrate, manufacturerscan incorporate pre-made components into electronic devices and systems.Because the semiconductor packages include sophisticated functionality,electronic devices can be manufactured using less expensive componentsand a streamlined manufacturing process. The resulting devices are lesslikely to fail and less expensive to manufacture resulting in a lowercost for consumers.

FIGS. 16 a-16 e illustrate forming a SiP module with vertically orienteddiscrete devices disposed between the bottom substrate and interposersubstrate. FIG. 16 a illustrates formation of SiP submodules 500 fromsubstrate 150, similar to FIG. 2 c . However, after mounting discretedevices 162 and semiconductor die 104 over substrate 150, the substrateis flipped for mounting of CCSB 214 and discrete devices 510. Similar todiscrete devices 162, discrete devices 510 can be any desired discreteelectrical component, e.g., capacitor, inductor, resistor, diode,transistor, etc. CCSB 214 are formed and mounted as in FIG. 3 b , butare disposed on conductive layer 156 of substrate 150 rather thanconductive layer 204 of substrate 200. In other embodiments, other typesof vertical interconnect structures are used instead of CCSB, e.g.,solder bumps, stud bumps, copper balls, copper posts, or conductivepillars. Discrete devices 510 and CCSB 214 can be initially mounted oneither substrate 150 or substrate 200 before assembling the twosubstrates into a SiP module.

Discrete devices 510 are similar to discrete devices 162, but mayinclude different dimensions depending on the requirements of thespecific embodiments. For instance, discrete devices 510 may need tohave shorter lengths between the terminals to fit lengthwise betweensubstrates 150 and 200. The thickness of discrete devices 510 may beincreased in another dimension to make up for the lower length, andcreate a discrete device with a substantially similar overall volume. Inother embodiments, discrete devices 510 are simply smaller devices thandiscrete devices 162.

Discrete devices 510 include solder paste 166 on both terminals. Solderpaste 166 can be any suitable material that is electrically conductiveand provides mechanical coupling between discrete devices 510 andsubstrate 150 and 200. Solder paste 166 can be solder melted onto theterminals of discrete devices 510, a solder paste with solder particlessuspended in flux, a conductive adhesive, or any other suitablecomposition. In one embodiment, discrete devices 510 are dipped into acontainer of solder paste 166 to apply the solder paste onto theterminals. In another embodiment, solder paste 166 is printed onto thesubstrates.

Substrate 150 is singulated into SiP submodules 500 as in FIG. 2 d .Then in FIG. 16 b , SiP submodules 500 are mounted onto substrate 200 asin FIG. 4 a . Solder paste 166 and the fusible shell of CCSB 214 arereflowed to mechanically and electrically connect SiP modules 500 tosubstrate 200. Portions of conductive layer 156 are electrically coupledto portions of conductive layer 204 through discrete devices 510. Bothdiscrete devices 510 and CCSB 214 provide electrical and mechanicalconnection between substrate 150 and substrate 200.

In FIG. 16 c , encapsulant 256 is deposited over substrate 200 and SiPsubmodules 520 as in FIG. 4 b . Encapsulant 256 flows between substrate150 and substrate 200, surrounding CCSB 214 and discrete devices 510. InFIG. 16 d , the panel is singulated into individual SiP modules 530 asin FIG. 4 c.

FIG. 16 e illustrates an individual SiP module 530 with verticallyoriented discrete devices 510. Discrete devices 510 provide anelectrical path from substrate 150 to substrate 200 as well asperforming a desired electrical function. Orienting discrete devices 510vertically between substrate 150 and 200 saves space relative to havinga horizontally oriented discrete device in combination with anadditional CCSB 214 for vertical interconnect. Discrete devices 510accomplish both vertical interconnect and a desired electrical function.

FIGS. 17 a and 17 b illustrate using horizontally oriented discretedevices 162 as vertical interconnects between substrates 150 and 200.SiP module 550 in FIG. 17 a is manufactured similarly to the above SiPmodules. However, the horizontally oriented discrete devices 552 and 554are directly electrically coupled both to substrate 150 and substrate200.

Discrete devices 552 and 554 are first disposed on one of substrate 150or 200. The discrete devices can have either one or both terminalsmechanically and electrically coupled to the first substrate 150 or 200by solder paste 166. Solder paste 166 is also disposed on the secondsubstrate 150 or 200 at locations where the second substrate is to becoupled to discrete devices 552 and 554. The upper SiP submodule isdisposed over substrate 200, and solder paste 166 is reflowed to meltthe solder between substrate 150, substrate 200, and discrete devices552 and 554.

Discrete devices 552 and 554 can provide electrical connection betweensubstrates 150 and 200 both through the discrete devices and alsodirectly through terminals of the discrete devices. The left terminal ofdiscrete device 552 is directly coupled to conductive layer 204 ofsubstrate 200. The contact pad of conductive layer 204 coupled to theleft terminal of discrete device 552 is coupled to a contact pad ofsubstrate 150 through the discrete device. Conductive layer 204 hasanother contact pad directly coupled to the right terminal of discretedevice 552, as does conductive layer 156 of substrate 150.

Conductive layer 156 of substrate 150 is directly coupled to one contactpad of substrate 200 through the right terminal of discrete device 552,and is coupled to a second contact pad of substrate 200 through thediscrete device. On the other hand, discrete device 554 has one terminalonly coupled to substrate 150 and a second terminal only coupled tosubstrate 200. Discrete device 554 couples the substrates togetherthrough the discrete device without providing an additional directconnection. Every terminal of a discrete device can be coupled to eitherof substrate 150 or substrate 200, or both.

Having only one terminal of a discrete device mechanically coupled bysolder paste 166 is normally enough to support the discrete devicecantilevered over the substrate during manufacturing. However, inembodiments where additional mechanical support is needed prior tohaving the second terminal coupled to the second substrate, or prior toencapsulant 256 being deposited, a non-conductive material or adhesive562 can be used to mechanically support the discrete devices withoutproviding electrical connection. Non-conductive material 562 can alsoenhance electrical isolation.

FIG. 17 b illustrates SiP module 560. Adhesive 562 is initially used tomount discrete devices 564 and 566 to substrate 150 when forming the topSiP submodule. Even though the circuit design only calls for a singleterminal of each of discrete devices 564 and 566 to be coupled tosubstrate 150, adhesive 562 adds strength to the mechanical connectionand increases manufacturing yields. The connection to the secondsubstrate, substrate 200 in this example, can include adhesive 562 on anunused second terminal of the discrete devices as illustrated withdiscrete device 566, or the second terminals can be left floating ifunused as illustrated with discrete device 564.

FIG. 18 illustrates discrete devices 572, 574, 576, and 578 supportingsubstrate 150 during the manufacturing process. Substrate 150 isdisposed on substrate 200 with discrete devices 572-578 already mountedon one of the two substrates. Substrate 150 rests on discrete devices572-578 or on solder paste disposed between the two. Solder paste 166 isreflowed to mechanically attach substrate 150 to substrate 200 throughdiscrete devices 572-578.

If no electrical connection is required between substrate 150 andsubstrate 200 through any one of the discrete devices, substrate 150 canbe allowed to rest on the discrete device without any solder paste andwithout conductive layer 156 having a contact pad over the terminal, asillustrated with discrete device 578. Additional vertical interconnectstructures, such as CCSB 214, may or may not be needed depending on therequirements of the particular circuit being implemented.

FIG. 19 illustrates SiP module 580 with discrete devices 582, 584, and586 supporting substrate 588 over the bottom substrate duringmanufacture. A vertically oriented discrete device 510 also contributesto supporting substrate 588 over substrate 200. Substrate 588 is smallerthan substrate 200 to allow room for taller components around theoutside of the package rather than including an opening over tallercomponents as with substrate 150. In other embodiments, any of the aboveor below disclosed SiP modules can be made with two substrates havingessentially the same footprint without openings if all desiredcomponents fit vertically between the two substrates.

FIG. 20 illustrates SiP module 590 with inductor 210 embedded within anopening of substrate 290, similar to FIG. 11 c above. Vertical discretedevices 510 provide desired electrical functionality along withelectrical interconnection between the two substrates.

FIG. 21 illustrates SiP module 600 with inductor 210 embedded in anopening of substrate 290 as in FIG. 20 . However, inductor 210 is shortenough that no opening in the top substrate 602 is required. Substrate602 extends completely over inductor 210. Clearance is provided by anopening in the bottom substrate 290 rather than in the top substrate602.

FIG. 22 illustrates SiP module 610 with shielding layer 612 depositedover the SiP module. Any of the above embodiments can have a conductivelayer sputtered over the package during manufacturing to provide anelectromagnetic interference reducing capability. Shielding layer 612can be electrically coupled to ground through any of the conductivelayers of the substrates extending to the edge of the substrate. Thesputtered metal of shielding layer 612 contacts any number of theexposed conductive layers at the edges of the substrates.

Any of the above SiP modules is mounted on a substrate and integratedinto an electrical system as shown in FIGS. 15 a and 15 b . Havingcomponents electrically coupled vertically within the SiP moduleprovides additional electrical paths through components that would beutilized anyway, without requiring additional vertical interconnectstructures. The overall footprint of the devices is reduced by reducingthe number of vertical interconnect structures required to be disposedside-by-side between substrates of the SiP modules. In addition,electrical performance is improved due to the shorter electrical paths.Electrical signals flow directly through a discrete device between thesubstrates, rather than having to flow through the discrete device andthen over to a vertical interconnect structure.

The illustrated component layouts are not intended to be limiting. Anyof the above SiP modules can be formed with additional passivecomponents disposed on any of the substrates. Any of the above SiPmodules can be formed with a semiconductor die on either of thesubstrates, or with no semiconductor die at all. Any potentialcombination of active and passive components is contemplated within thescope of the present disclosure.

While one or more embodiments of the present invention have beenillustrated in detail, the skilled artisan will appreciate thatmodifications and adaptations to those embodiments may be made withoutdeparting from the scope of the present invention as set forth in thefollowing claims.

What is claimed:
 1. A method of making a semiconductor device,comprising: providing a first substrate; disposing a first electricalcomponent over the first substrate with a first terminal of the firstelectrical component oriented toward the first substrate and a secondterminal of the first electrical component oriented away from the firstsubstrate, wherein the first electrical component is a discrete activeor passive device; disposing a first solder material between the firstterminal of the first electrical component and the first substrate;disposing a second substrate over the first substrate with the firstelectrical component between the first substrate and second substrate;disposing a second solder material between the second terminal of thefirst electrical component and the second substrate; and depositing anencapsulant between the first substrate and second substrate and aroundthe first electrical component.
 2. The method of claim 1, furtherincluding forming a shielding layer over the encapsulant, wherein theshielding layer is electrically connected to the first substrate orsecond substrate.
 3. The method of claim 1, further including: formingan opening through the first substrate or second substrate; anddisposing a second electrical component between the first substrate andsecond substrate with the second electrical component extending into theopening.
 4. The method of claim 1, wherein the second substrate iselectrically coupled to the first substrate through the first electricalcomponent.
 5. The method of claim 1, further including disposing asecond electrical component over the second substrate opposite the firstelectrical component.
 6. A method of making a semiconductor device,comprising: providing a first substrate; disposing a first electricalcomponent over the first substrate with a first terminal of the firstelectrical component oriented toward the first substrate and a secondterminal of the first electrical component oriented away from the firstsubstrate; disposing a second substrate over the first substrate withthe first electrical component between the first substrate and secondsubstrate; forming an opening through the first substrate or secondsubstrate; and singulating the first substrate to create a semiconductorpackage with the first electrical component and second substrate.
 7. Themethod of claim 6, further including: electrically coupling the firstterminal of the first electrical component to the first substrate; andelectrically coupling the second terminal of the first electricalcomponent to the second substrate.
 8. The method of claim 6, furtherincluding depositing an encapsulant over the first substrate and secondsubstrate.
 9. The method of claim 8, further including forming ashielding layer over the encapsulant.
 10. The method of claim 6, furtherincluding disposing a second electrical component between the firstsubstrate and second substrate with the second electrical componentextending into the opening.
 11. The method of claim 6, further includingdisposing a second electrical component over the second substrateopposite the first electrical component.
 12. A semiconductor device,comprising: a first substrate; a second substrate; a first electricalcomponent disposed between the first substrate and second substrate witha first terminal of the first electrical component oriented toward thefirst substrate and a second terminal of the first electrical componentoriented toward the second substrate, wherein the first electricalcomponent is a discrete active or passive device; a first soldermaterial disposed between the first terminal of the first electricalcomponent and the first substrate; a second solder material disposedbetween the second terminal of the first electrical component and thesecond substrate; and an encapsulant deposited over the first substrate,second substrate, and first electrical component.
 13. The semiconductordevice of claim 12, further including a shielding layer formed over theencapsulant, wherein the shielding layer is electrically connected tothe first substrate or second substrate.
 14. The semiconductor device ofclaim 12, further including: an opening formed through the firstsubstrate or second substrate; and a second electrical componentdisposed between the first substrate and second substrate with thesecond electrical component extending into the opening.
 15. Thesemiconductor device of claim 12, wherein the second substrate iselectrically coupled to the first substrate through the first electricalcomponent.
 16. The semiconductor device of claim 12, further including asecond electrical component disposed over the second substrate oppositethe first electrical component.
 17. A semiconductor device, comprising:a first substrate; a second substrate; an opening formed through thefirst substrate or second substrate; a first electrical componentdisposed between the first substrate and second substrate with a firstterminal of the first electrical component oriented toward the firstsubstrate and a second terminal of the first electrical componentoriented toward the second substrate; and an encapsulant deposited overthe first substrate, second substrate, and first electrical component,wherein a surface of the encapsulant is coplanar to a surface of thefirst substrate.
 18. The semiconductor device of claim 17, wherein thefirst substrate is electrically coupled to the second substrate throughthe first electrical component.
 19. The semiconductor device of claim17, wherein the surface of the encapsulant is coplanar to a surface ofthe second substrate.
 20. The semiconductor device of claim 19, furtherincluding a shielding layer formed over the encapsulant.
 21. Thesemiconductor device of claim 17, further including a second electricalcomponent disposed between the first substrate and second substrate withthe second electrical component extending into the opening.